EXPANDING STOCK TANK

[x rated]

Hey guys just starting to get in to the iba stuff and have been reading alot about aux. fuel tanks but has anybody ever taken a stock tank and split it in half and adding an inch or so to width and heighth. should net a gallon or or gallon and half. with the absence of a fuel gauge it should be farley simple as far as metal work goes. Im know expert by anymeans but i dont see a problem with it. Ive got a buddy thats quit the metal worker might try and buy a used tank and give it a try. would love to hear some imput from you guys with a little more knowledge the me. by the way i ride an 03 1800r.

[Todd2]

Some have replaced the stock air box and pair valve system to open up room under the tank. Then a new panel is welded in to use that space. I think they net 1/2 to 1 1/2 gallons, depending on who did the mod. Other bike owners have cut the bottom out of their tank and welded it to the bottom of a larger tank (Magna to Valk, if I remember correctly). I do not know of anyone successfully cutting an X tank and enlarging it, as you describe. Seems like a lot of work, but if you try it, please take pics of the process and post it here. Thanks! Sorry I wasn't of more help. Good luck.

Todd

[x rated]

hey todd2 dont be sorry. ive seen it done with harley tanks were they split it down the middle and weld in a 1-2 peice. yes the stock x tank would be harder with the guages and filler cap and bezel the way its inset. but harder just means a little rewarding when you pull it off right? wasnt it your post on the BBG I was reading last right, with that Im sure you can relate to taking on the challange. If i can come up with a 2nd tank that I can get for a reasonable price Im gonna try it. I let you know how it goes.

[michael7276]

With the slip mounts on the tank, it would seem you'd have to relocate these. I've always thought it would be easier to expand the sides.

[Todd2]

X rated,

I wish you luck in your tank expansion. Take pics, I know a lot of X'ers have expressed an interest in enlarging their tanks. I'm sure we can learn from your experiences (besides I want to see how its done and what it looks like).

Todd

[x rated]

will do, Im looking for a used tank, it summer and im not gonna tear the bike apart so if i can find one for a resonable price ill start on soon.

[x rated]

IM talking to another member about a tank, hopefully we can come to a reasonable price. Looking forward to trying to do this. I did some ruff measuring and I think I can add 2" width an and 1" to the hieghth. If I add to the bottom were the desmog is I think I can get 7.6 to 8 gallons from the tank. Thats a ruff but bet its fairly close. Which should get me in the 300 mile range per tank, I figure about 270 to 280 before the light comes on.

[x rated]

well I bought a tank on ebay tonight so hopefully it will be here with by the end of next week. Ill probably get started on it the week after labore day. Ill take pics. Any Ideas on the best way to start this project, Ive got a few but would love to hear some imput on what you guys have been thinking.

[x rated]

Got my new tank today. Im stripping the paint of as we speak. Probably start tearing into it next week.

[Todd2]

Don't forget the camera along the way! :wink:
Good luck.

Todd

[mountainbike]

Todd2

Can you talk a bit more about expanding the stock tank? I've replaced the air box and have the extra room.

Thanks

[Todd2]

Mountainbike,

I have not made this mod, but others have removed the PAIR system from the top right side of the engine and replaced the stock air box with one that does not run up under the tank like the stock airbox does. This leaves a large open area under the tank, unoccupied by anything. Others have then cut out the indentation in the tank in this area and replaced it with sheet metal to look more like the left hand side (now utilysing the open space for gas). This requires sheet metal and welding experience.

One concern is getting all the gas from the right hand side, past the backbone frame member, to the left hand side where the fuel pump is. This can be accomplished by adding two bulkhead fittings near the rear of the tank bottom (one on each side, L & R) and plumbing them together via a tube under the backbone frame member. (The tube would then have to be disconnected to remove the tank.)

There is currently a member (kxkchoppers - http://www.vtxoa.com/forums/viewtopic.php?t=143059 ) on the General Board that is claiming to be able to mod. the tank for a decent price. He appears to have the knowledge and capabilities to perform this work.

Good luck. Let us know what you decided to do and how much more fuel capacity you got.

Todd

[mountainbike]

Todd

That all makes sense. Kinda what it looked like to me as well. Add metal and feed gas to pump.

Now I've got a 1300. Not sure there's a PAIR system on it. Doesn't the PAIR deal with fuel injection?

After removing the stock air box there really is a ton of extra space. And in the mountains gas stations aren't always close together...

[Todd2]

Sorry Mountainbike, I was describing the 1800, which I have. I do not believe the 1300's have a PAIR system (its used to inject air into the exhaust for emissions). However, the concept is the same - change the bottom of the tank to take advantage of any open space you have. Also, I do not know where your fuel line hooks in or if you would encounter any difficulty with fuel transfer from left to right, past the frame. But you get the general idea I was trying to convey.

Good Luck.

Todd

[mountainbike]

Yeah thanks, Todd.

Asked the same question to the 1300 board. Got a few good links. Think I just need to take the tank off and noodle around a bit.

[x rated]

they say you dont need to do the level hose. that the tank actually feeds at the back to both sides and will level out by it self. On the 1800 you can get 1.5-1.8 gallons on the smaller c tank according to some other members that have done the mod on after doing the desmog. Im doing this and adding another 2 inches to the front and tappering back to stock width in rear. should net me some were in the neighbor hood of 8.3-8.7 gallons total. get me up to 320-350 miles.

[curve10780]

The 1300 does have the pair valve system. You can remove it and install the blockoff plates for more room. All the pair valve does is for air into the top of the cylinders to allow excess gases to burn up and not create backfire. I hope this is correct but I know my 1300 no longer has it and I'm also looking for alternatives for a larger tank.